Suzuki LT-A750XP/Z Supplementary Service Manual

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Engine
Type
Supplementary Service Manual

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LT-A750XP/ZK9 Supply 99501-47050-03E Cover 14 for PS printing (Back: 3 mm) 5/1
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Pantone 303C Pantone 485 Pantone 294
(CMYK: 100, 0, 0, 85) (CMYK: 0, 100, 100, 0) (CMYK: 100, 70, 0, 0)
DIC 179
3 mm
LT-A750XP/Z
Printed in U.S.A.
K9
K9
9 9 5 0 1 - 4 7 0 5 0 - 0 3 E
LT-A750XP/Z
SUPPLEMENTARY SERVICE MANUAL
SUPPLEMENTARY SERVICE MANUAL
USE THIS MANUAL WITH:
LT-A750X/Z SERVICE MANUAL (99500-47021-03E)
LT-A750XP/ZK9 Supply 99501-47050-03E Cover 23 for PS printing (Back: 3 mm) 5/1
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FOREWORD
This SUPPLEMENTARY SERVICE MANUAL is a supplement to SUZUKI LT-A750X/Z SERVICE MANUAL.
It has been prepared exclusively for the following applicable model.
Applicable model:
LT-A750XK9
This supplementary service manual describes only service information which differ from that of the main man-
ual. Therefore, whenever servicing the above applicable model, consult this supplement first. And for any sec-
tion, item or description not found in this supplement, refer to the main manual below.
Main Manual:
Other information considered as generally known is not included.
Read the GENERAL INFORMATION section to familiarize yourself with the vehicle and its maintenance. Use
this section as well as other sections to use as a guide for proper inspection and service.
This manual will help you know the vehicle better so that you can assure your customers of fast and reliable ser-
vice.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2009
Manual Name Manual No.
LT-A750X/ZK9 SERVICE MANUAL 99500-47021-03E
* This manual has been prepared on the basis of the latest specifications at the time of publication. If modifi-
cations have been made since then, differences may exist between the content of this manual and the
actual vehicle.
* Illustrations in this manual are used to show the basic principles of operation and work procedures. They
may not represent the actual vehicle exactly in detail.
* This manual is written for persons who have enough knowledge, skills and tools, including special tools, for
servicing SUZUKI vehicles. If you do not have the proper knowledge and tools, ask your authorized
SUZUKI motorcycle dealer to help you.
WARNING
!
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the rider.
Prepared by
March, 2009
Part No. 99501-47050-03E
Printed in U.S.A.
132
00
0
1
2
3
4
5
6
9
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Service Data...........................................................0C-1
Engine ......................................................................... 1-i
Precautions ............................................................... 1-*
Engine General Information and Diagnosis ............1A-*
Emission Control Devices .......................................1B-*
Engine Electrical Devices....................................... 1C-*
Engine Mechanical................................................. 1D-*
Engine Lubrication System .....................................1E-*
Engine Cooling System...........................................1F-*
Fuel System ........................................................... 1G-*
Ignition System....................................................... 1H-*
Starting System....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ......................................................1K-*
Suspension................................................................. 2-*
Precautions ............................................................... 2-*
Suspension General Diagnosis...............................2A-*
Front Suspension ....................................................2B-*
Rear Suspension.................................................... 2C-*
Wheels and Tires ................................................... 2D-*
Driveline / Axle ........................................................... 3-i
Precautions ............................................................... 3-*
Drive Chain / Drive Train / Drive Shaft ................... 3A-1
Differential ...............................................................3B-*
Transfer.................................................................. 3C-*
Propeller Shafts...................................................... 3D-*
Brake ........................................................................... 4-i
Precautions ............................................................... 4-*
Brake Control System and Diagnosis ....................4A-1
Front Brakes............................................................4B-*
Rear Brakes ........................................................... 4C-*
Parking Brake......................................................... 4D-*
Transmission / Transaxle .......................................... 5-*
Precautions ............................................................... 5-*
Automatic Transmission..........................................5A-*
Steering....................................................................... 6-i
Precautions .............................................................. 6-1
Steering General Diagnosis ................................... 6A-1
Steering / Handlebar .............................................. 6B-1
Power Assisted Steering System ...........................6C-1
Body and Accessories............................................... 9-i
Precautions ...............................................................9-*
Wiring Systems ......................................................9A-1
Lighting Systems.................................................... 9B-*
Combination Meter / Fuel Meter / Horn .................. 9C-*
Exterior Parts ......................................................... 9D-*
Body Structure .......................................................9E-1
TABLE OF CONTENTS
NOTE
For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same
sections of the service manual mentioned in the “FOREWORD” of this manual.
Table of Contents 00- i
00
Section 00
CONTENTS
Precautions
Precautions ...............................................00-1
Precautions........................................................... 00-1
Warning / Caution / Note...................................... 00-*
General Precautions ............................................00-*
Precautions for Electrical Circuit Service .............00-*
Precautions for EPS (LT-A750XP/ZK9) .............. 00-1
NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual
mentioned in the “FOREWORD” of this manual.
00-1 Precautions:
Precauti ons
Precautions
Precautions
Precautions for EPS (LT-A750XP/ZK9)
B931G40000004
EPS Wiring
The EPS parts are connected to various lead wires.
The coupler and lead wire connections, as well as the
lead wire and wire harness routings must be done
correctly. Make sure that the proper clamps are used
and positioned correctly.
NOTE
If all of the connections are not properly
connected, the EPS may not operate
correctly. For connector and coupler
precautions. Refer to “Precautions for
Electrical Circuit Service in related manual”.
EPS Control Unit / EPS Body Assembly
Never allow dust or water to contact the EPS control
unit and EPS body assembly.
Since each component is a high-precision part, great
care should be taken not to apply any service impacts
during removal and installation.
The EPS control unit and EPS body assembly cannot
be disassembled. Replace the whole unit with a new
one.
I931H1000004-01
I931H1000003-02
I931H1000005-01
Table of Contents 0- i
0
Section 0
CONTENTS
General Information
General Information ................................ 0A-1
General Description .............................................0A-1
Symbols ...............................................................0A-*
Abbreviations .......................................................0A-*
SAE-to-Former SUZUKI Term .............................0A-*
Vehicle Side View ................................................0A-*
Vehicle Identification Number ..............................0A-*
Fuel and Oil Recommendation ............................0A-*
Engine Coolant Recommendation .......................0A-*
BREAK-IN Procedures.........................................0A-*
Country and Area Codes .....................................0A-*
Wire Color Symbols .............................................0A-*
Warning, Caution and Information Labels
Location .............................................................0A-*
Abbreviations (LT-A750XP/ZK9)......................... 0A-1
Vehicle Side View (LT-A750XP/ZK9).................. 0A-1
Country and Area Codes (LT-A750XP/ZK9)....... 0A-1
Warning, Caution and Information Labels
Location (LT-A750XP/ZK9)...............................0A-2
Component Location ........................................... 0A-*
Electrical Components Location ..........................0A-*
Specifications.......................................................0A-3
Specifications (LT-A750X/ZK8)............................0A-*
Specifications (LT-A750X/ZK9)............................0A-*
Specifications (LT-A750XP/ZK9) ........................0A-3
Special Tools and Equipment ............................. 0A-*
Special Tools and Equipment .............................0A-5
Special Tool ........................................................ 0A-5
Maintenance and Lubrication................. 0B-1
Precautions........................................................... 0B-*
Precautions for Maintenance ...............................0B-*
General Description ............................................. 0B-*
Recommended Fluids and Lubricants..................0B-*
Scheduled Maintenance ...................................... 0B-*
Periodic Maintenance Schedule Chart.................0B-*
Lubrication Points ................................................0B-*
Repair Instructions ..............................................0B-1
Air Cleaner Element Inspection and Cleaning .....0B-*
Exhaust Pipe Bolt and Muffler Bolt Inspection .....0B-*
Valve Clearance Inspection and Adjustment .......0B-*
Spark Plug Replacement .....................................0B-*
Spark Plug Inspection and Cleaning....................0B-*
Spark Arrester Cleaning.......................................0B-*
Fuel Line Inspection ............................................ 0B-*
Engine Oil and Filter Replacement ..................... 0B-*
Front Differential Gear Oil Inspection.................. 0B-*
Front Differential Gear Oil Replacement ............. 0B-*
Final Gear Oil Inspection..................................... 0B-*
Final Gear Oil Replacement................................ 0B-*
Throttle Cable Play Inspection and
Adjustment ........................................................ 0B-*
Throttle Body Inspection ..................................... 0B-*
Cooling System Inspection.................................. 0B-*
Drive V-belt Inspection and Replacement........... 0B-*
Drive Shaft Boots Inspection............................... 0B-*
Front Brake System Inspection ........................... 0B-*
Rear Brake Pedal / Rear Brake (Parking
Brake) Lever Inspection and Adjustment .......... 0B-*
Rear Brake Friction Plate Wear Limit
Inspection.......................................................... 0B-*
Tire Inspection..................................................... 0B-*
Steering System Inspection ................................ 0B-*
Toe Adjustment ................................................... 0B-*
Suspensions Inspection ...................................... 0B-*
Chassis Bolt and Nut Inspection ......................... 0B-*
Compression Pressure Check ............................ 0B-*
Oil Pressure Check ............................................. 0B-*
SDS Check.......................................................... 0B-*
Automatic Clutch Inspection................................ 0B-*
Air Cleaner Element Inspection and Cleaning
(LT-A750XP/ZK9)..............................................0B-1
Steering System Inspection (LT-A750XP/
ZK9) ..................................................................0B-1
Toe Adjustment (LT-A750XP/ZK9) .....................0B-2
Chassis Bolt and Nut Inspection (LT-A750XP/
ZK9) ..................................................................0B-3
Specifications.......................................................0B-4
Tightening Torque Specifications........................0B-4
Special Tools and Equipment ............................. 0B-*
Recommended Service Material ......................... 0B-*
Special Tool ........................................................ 0B-*
Service Data ............................................. 0C-1
Specifications.......................................................0C-1
Service Data........................................................ 0C-*
Tightening Torque List ........................................ 0C-*
Service Data (LT-A750XP/ZK9) ..........................0C-1
Tightening Torque List (LT-A750XP/ZK9)...........0C-7
NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual
mentioned in the “FOREWORD” of this manual.
0A-1 General Information:
General Info rmation
General Information
General Description
Abbreviations (LT-A750XP/ZK9)
B931G40101012
NOTE
Please refer to the LT-A750XK9 (’09-model) service manual for other abbreviations which are not given
in this manual.
E:
EPS: Electronic Power Steering
Vehicle Side View (LT-A750XP/ZK9)
B931G40101013
NOTE
Difference between illustration and actual
motorcycles may exist depending on the
markets.
SUZUKI LT-A750XP (2009-model)
Right Side
Left Side
Country and Area Codes (LT-A750XP/ZK9)
B931G40101014
The following codes stand for the applicable country(-ies) and area(-s).
I931G3010001-01
I931G3010002-01
Code Country or Area Effective Frame No.
LT-A750XPK9 (P-17) Sweden
5SAAR41P97100001 –
LT-A750XPK9 (P-24) Australia
LT-A750XPK9 (P-28) Canada
LT-A750XPK9 (P-33) U.S.A.
LT-A750XPZK9 (P-17) Sweden
LT-A750XPZK9 (P-24) Australia
LT-A750XPZK9 (P-28) Canada
LT-A750XPZK9 (P-33) U.S.A.
General Information: 0A-2
Warning, Caution and Information Labels Location (LT-A750XP/ZK9)
B931G40101015
5
14
17, 18
11
9
6
3
7
8
10
12, 13
15, 16
4
1, 20, 21
22, 23
24
19
25
2, 26, 27
[A]
I931H1010010-03
1. Certification plate (English) For P-24, 33 15. Front carrier warning label (English) For P-24, 33
2. Information label (English) For P-33 16. Front carrier warning label (English/French) For P-17, 28
3. Gearshift label (English) For P-17, 24, 28, 33 17. Rear carrier warning label (English) For P-24, 33
4. Gearshift label (French) For P-28 18. Rear carrier warning label (English/French) For P-17, 28
5. Tire air pressure label (English) For P-17, 24, 28, 33 19. ICES Canada label (English/French) For P-28
6. Tire air pressure label and warning no-
passenger label (French)
For P-28
20. Compliance label (English)
For P-28
7. General warning & AGE, 16 label (English) For P-17, 24, 28, 33 21. I.D. plate (English) For P-17
8. General warning label (French) For P-28 22. Cooling fan label (English) For P-24, 33
9. Warning no-passenger label (English) For P-17, 24, 28, 33 23. Cooling fan label (English/French) For P-17, 28
10. AGE, 16 label (French) For P-28 24. Compliance label (English/French) For P-28
11. Manual notice label (English) For P-33 25. ANSI certification label (Right side of frame) For P-33
12. Max AMP caution label (English) For P-24, 33 26. Information label (English) For P-28
13. Max AMP caution label (English/French)
For P-17, 28
27. Information label (French)
(Right side of frame)
For P-28
14. Fuel caution label (English) For P-24 [A]: Left side of frame
0A-3 General Information:
Specifications
Specifications (LT-A750XP/ZK9)
B931G40107003
NOTE
These specifications are subject to change without notice.
Dimensions and curb mass
Engine
Drive train
Item Specification Remark
Overall length
2 115 mm (83.3 in) P-28, 33
2 165 mm (85.2 in) P-17, 24
Overall width
1 210 mm (47.6 in) P-28, 33
1 250 mm (49.2 in) P-17, 24
Overall height 1 285 mm (50.6 in)
Wheelbase 1 285 mm (50.6 in)
Ground clearance 260 mm (10.2 in)
Seat height 920 mm (36.2 in)
Curb mass
305 kg (672 lbs) P-28, 33
307 kg (677 lbs) P-17, 24
Front track 940 mm (37.0 in)
Rear track 920 mm (36.2 in)
Item Specification Remark
Type 4-stroke, liquid-cooled, DOHC
Number of cylinders 1
Bore 104.0 mm (4.094 in)
Stroke 85.0 mm (3.346 in)
Displacement 722 cm
3
(44.1 cu. in)
Compression ratio 10.0 : 1
Fuel system Fuel injection
Air cleaner Paper element
Starter system Electric starter
Lubrication system Wet sump
Idle speed 1 300 ± 100 r/min
Item Specification Remark
Clutch Wet shoe, automatic, centrifugal type
Transmission CVT (V-belt)
Transfer 2-speed forward with reverse
Gearshift
pattern
Transmission Automatic
Transfer L-H-N-R (Hand operated)
Automatic transmission ratio Variable change (2.763 – 0.78)
Secondary reduction ratio 2.158 (40/21 x 17/15)
Final reduction ratio
(Front & Rear)
3.600 (36/10)
Transfer gear
ratio
Low 2.562 (41/16)
High 1.240 (31/25)
Reverse 1.882 (32/17)
Drive system Shaft drive
General Information: 0A-4
Chassis
Electrical
Capacities
Item Specification Remark
Front suspension Independent, double wishbone, coil spring, oil damped
Rear suspension Independent, double wishbone, coil spring, oil damped
Front wheel travel 170.5 mm (6.7 in)
Rear wheel travel 195 mm (7.7 in)
Caster 3.3°
Trail 16.7 mm (0.66 in)
Toe-out 5 mm (0.20 in)
Camber –1.3°
Steering angle 46° (right & left)
Turning radius 3.1 m (10.2 ft)
Front brake Disc brake, twin
Rear brake Sealed oil-bathed multi-disc
Front tire size AT25 x 8-12, tubeless
Rear tire size AT25 x 10-12, tubeless
Item Specification Remark
Ignition type Electronic ignition (CDI)
Ignition timing 7° B.T.D.C. at 1 300 r/min
Spark plug NGK CR6E or DENSO U20ESR-N
Battery 12 V 64.8 kC (18 Ah)/10 HR
Generator Three-phase A.C. generator
Main fuse 30 A
Fuse 10/10/10/10/15/15 A
EPS fuse 40 A
Headlight 12 V 35/35 W x 2
Auxiliary light 12 V 35/35 W
Brake light/Taillight 12 V 21/5 W
Reversing light 12 V 21 W P-17
Speedometer light LED
Neutral indicator light LED
High beam indicator light LED P-17
Coolant temperature/FI
indicator light
LED
Reverse indicator light LED
Diff-lock indicator light LED
EPS indicator light LED
Item Specification Remark
Fuel tank 17.5 L (4.6/3.8 US/lmp gal)
Engine oil
Oil change 2 300 ml (2.4/2.0 US/lmp qt)
With filter
change
2 500 ml (2.6/2.2 US/lmp qt)
Overhaul 3 000 ml (3.2/2.6 US/lmp qt)
Differential gear oil 500 ml (16.9/17.6 US/lmp oz)
Final gear oil 770 ml (26.0/27.1 US/lmp oz)
Coolant 2.5 L (2.6/2.2 US/lmp qt)
0A-5 General Information:
Special Tools and Equipment
Special Tool
B931G40108002
09900–06107
Snap ring remover
(Open type)
09900–20102
Vernier calipers (200
mm)
09900–25008
Multi circuit tester set
09900–25009
Needle-point probe
set
09904–41010
SUZUKI Diagnostic
system set
09924–84521
Bearing installer set
09930–30721
Rotor remover
09930–44530
Rotor holder
09930–82710
Mode select switch
09930–82720
Mode selection switch
09942–72410
Tie-rod end remover
09942–83110
Clip remover
09944–36011
Steering wheel
remover
99565–01010–020
CD-ROM Ver.20
Maintenance and Lubrication: 0B-1
General Info rmation
Maintenance and Lubrication
Repair Instructions
Air Cleaner Element Inspection and Cleaning
(LT-A750XP/ZK9)
B931G40206030
Clean element
Every 1 000 km (600 miles, 3 months)
If the air cleaner is clogged with dust, intake resistance
will be increased, with a resultant decrease in power
output and an increase in fuel consumption. Check and
clean the air cleaner element in the following manner.
CAUTION
!
If driving under dusty conditions, clean the
air cleaner element more frequently. The
surest way to accelerate engine wear is to
operate the engine without the element or
to use a torn element. Make sure that the
air cleaner is in good condition at all times.
Life of the engine depends largely on this
component.
Inspect the air cleaner element for tears. A
torn element must be replaced.
1) Remove the air cleaner element. Refer to “Air
Cleaner Element Removal and Installation in Section
1D in related manual”.
2) Separate the polyurethane from element.
3) Fill a wash pan of a proper size with a non-
flammable cleaning solvent. Immerse the air cleaner
element in the cleaning solvent and wash it.
4) Press the air cleaner element between the palms of
both hands to remove the excess solvent: do not
twist or wring the element or it will tear.
5) Immerse the element in motor oil, and then squeeze
out the excess oil leaving the element slightly wet.
6) After cleaning the air cleaner element, reinstall the
removed parts.
7) Drain water from the air cleaner box by removing the
drain plug.
8) Reinstall the drain plug.
Steering System Inspection (LT-A750XP/ZK9)
B931G40206031
Inspect steering system
Initially at 200 km (100 miles, 1 month) and every 1
000 km (600 miles, 3 months) thereafter
Steering should be adjusted properly for smooth turning
of handlebars and safe running.
1) Place the vehicle on level ground.
2) Make sure the tire pressure for right and left tires in
the same and set to the proper specification.
3) Set the front wheels in the straight position.
4) Place a load of 75 kg (165 lbs) on the seat.
I831G1020002-01
“A”: Non-flammable cleaning solvent
“B”: Motor oil SAE #30 or SAE 10W-40
“A”
“B”
I931G3020009-01
I831G1020004-01
0B-2 Maintenance and Lubrication:
5) Measure the distances (“A” and “B”) between the
front wheels. Subtract the measurement of “A” from
that of “B” to find the toe-out. If the toe-out is not
within specification, adjust the tie-rod to the right or
left until the toe-out is within the specified range.
Toe-out (“B” – “A”)
Standard: 5 ± 4 mm (0.20 ± 0.16 in)
If the toe-out is out of specification, bring it into the
specified range. Refer to “Toe Adjustment (LT-A750XP/
ZK9) (Page 0B-2)”.
Toe Adjustment (LT-A750XP/ZK9)
B931G40206032
Adjust the toe-out as follows:
1) Loosen the lock-nuts (1), (2) on each tie-rod.
CAUTION
!
The lock-nuts (2) have left-hand threads.
When loosening and tightening the lock-
nuts, hold the tie-rod end with a open end
wrench.
NOTE
Hold the concave part “a” of tie-rod with a
wrench.
2) Temporarily tighten the four lock-nuts.
3) Check that the distances “C” and “D” are equal, as
shown. If the distances are not equal, adjust the tie-
rod to the right or left until the toe-out is within
specification. Check the toe-out again by measuring
distances “A” and “B”.
4) If the toe-out is not within specification, repeat the
adjustment as above until the proper toe-out is
obtained and distances “C” and “D” become equal.
5) After adjustment has been made, tighten the four
lock-nuts to the specified torque.
Tightening torque
Tie-rod lock-nut (a): 29 N·m (2.9 kgf-m, 21.0 lbf-
ft)
I931H1020057-01
FWD
“A”
“B”
I831G1020059-04
2
1
1
“a”
“a”
FWD
FWD
I931H1020079-02
“C”
Right angle
(90
°
)
FWD
“A”
“B”
“D”
I831G1020088-04
(a)
(a)
(a)
I831G1020089-01
Maintenance and Lubrication: 0B-3
Chassis Bolt and Nut Inspection (LT-A750XP/
ZK9)
B931G40206033
Tighten chassis bolt and nut
Initially at 200 km (100 miles, 1 month) and every 1
000 km (600 miles, 3 months) thereafter
Check that all chassis bolts and nuts are tightened to
their specified torque.
1 EPS body assembly mounting bolt (Upper) 26 Nm (2.6 kgf-m,
19.0 lbf-ft)
2 EPS body assembly mounting nut (Lower) 28 Nm (2.8 kgf-m,
20.0 lbf-ft)
3 Steering shaft bolt 26 Nm (2.6 kgf-m, 19.0 lbf-ft)
(a)
1
I931G3020001-01
(b)
2
I931G3020002-01
(a)
3
I931G3020003-01
4 Steering shaft upper nut 120 Nm (12.0 kgf-m, 87.0 lbf-ft)
5 Tie-rod lock-nut 29 Nm (2.9 kgf-m, 21.0 lbf-ft)
6 Rear stabilizer joint nut 60 Nm (6.0 kgf-m, 43.5 lbf-ft)
7 Rear brake pedal screw 4.5 Nm (0.45 kgf-m, 3.0 lbf-ft)
(c)
4
I931G3020004-02
(d)
5
(d)
5
I931G3020005-02
(e)
6
(e)
6
I931G3020007-02
(f)
7
I931G3020008-01
0B-4 Maintenance and Lubrication:
Specifications
Tightening Torque Specifications
B931G40207001
NOTE
The specified tightening torque is described in the following.
“Chassis Bolt and Nut Inspection (LT-A750XP/ZK9) (Page 0B-3)”
Reference:
For the tightening torque of fastener not specified in this section, refer to “Tightening Torque List (LT-A750XP/ZK9) in
Section 0C (Page 0C-7)”.
Fastening part
Tightening torque
Note
Nm kgf-m lbf-ft
Tie-rod lock-nut 29 2.9 21.0 )(Page 0B-2)
Service Data: 0C-1
General Info rmation
Service Data
Specifications
Service Data (LT-A750XP/ZK9)
B931G40307003
Valve + Valve Guide
Unit: mm (in)
Camshaft + Cylinder Head
Unit: mm (in)
Item Standard Limit
Valve diam.
IN. 36.0 (1.42)
EX. 33.0 (1.30)
Tappet clearance (When cold)
IN. 0.10 – 0.20 (0.004 – 0.008)
EX. 0.20 – 0.30 (0.008 – 0.012)
Valve guide to valve stem clearance
IN. 0.010 – 0.037 (0.0004 – 0.0015)
EX. 0.030 – 0.057 (0.0012 – 0.0022)
Valve guide I.D. IN. & EX. 5.500 – 5.512 (0.2165 – 0.2170)
Valve stem O.D.
IN. 5.475 – 5.490 (0.2156 – 0.2161)
EX. 5.455 – 5.470 (0.2148 – 0.2154)
Valve stem deflection IN. & EX. 0.35 (0.014)
Valve stem runout IN. & EX. 0.05 (0.002)
Valve head thickness IN. & EX. 0.5 (0.02)
Valve seat width IN. & EX. 0.9 – 1.1 (0.035 – 0.043)
Valve head radial runout IN. & EX. 0.03 (0.001)
Valve spring free length IN. & EX. 46.1 (1.81)
Valve spring tension IN. & EX.
182 – 210 N (18.6 – 21.4 kgf, 41.0 – 47.2 lbs)
at length 36.35 mm (1.43 in)
Item Standard Limit
Cam height
IN. 36.330 – 36.380 (1.4303 – 1.4323) 36.030 (1.4185)
EX. 35.300 – 35.350 (1.3898 – 1.3917) 35.000 (1.3780)
Camshaft journal oil clearance IN. & EX. 0.019 – 0.053 (0.0007 – 0.0021) 0.150 (0.0059)
Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 (0.8666 – 0.8671)
Camshaft journal O.D. IN. & EX. 21.972 – 21.993 (0.8650 – 0.8659)
Camshaft runout IN. & EX. 0.10 (0.004)
Cylinder head distortion 0.05 (0.002)
Cam drive idle gear/sprocket thrust
clearance
0.15 – 0.27 (0.006 – 0.011)
0C-2 Service Data:
Cylinder + Piston + Piston Ring
Unit: mm (in)
Conrod + Crankshaft
Unit: mm (in)
Oil Pump
Clutch
Unit: mm (in)
Item Standard Limit
Compression pressure
(Automatic-decomp. actuated)
Approx. 1 000 kPa (10.0 kgf/cm
2
, 142 psi)
Piston-to-cylinder clearance 0.030 – 0.040 (0.0012 – 0.0016) 0.120 (0.0047)
Cylinder bore 104.000 – 104.015 (4.09454.0951)
Nicks or
Scratches
Piston diam.
103.965 – 103.980 (4.09314.0937)
Measure at 15 mm (0.6 in) from the skirt end.
103.880 (4.0898)
Cylinder distortion 0.05 (0.002)
Piston ring free end gap
1st R Approx. 13.1 (0.52) 10.5 (0.41)
2nd RN Approx. 14.6 (0.57) 11.7 (0.46)
Piston ring end gap
1st R 0.10 – 0.25 (0.004 – 0.010) 0.50 (0.020)
2nd RN 0.10 – 0.25 (0.004 – 0.010) 0.50 (0.020)
Piston ring-to-groove clearance
1st 0.180 (0.0071)
2nd 0.150 (0.0059)
Piston ring groove width
1st
0.83 – 0.85 (0.0327 – 0.0335)
1.30 – 1.32 (0.0512 – 0.0520)
2nd 1.01 – 1.03 (0.0398 – 0.0406)
Oil 2.01 – 2.03 (0.0791 – 0.0799)
Piston ring thickness
1st
0.76 – 0.81 (0.0299 – 0.0319)
1.08 – 1.10 (0.0425 – 0.0433)
2nd 0.97 – 0.99 (0.0382 – 0.0390)
Piston pin bore I.D. 23.002 – 23.008 (0.9056 – 0.9058) 23.030 (0.9067)
Piston pin O.D. 22.992 – 23.000 (0.9052 – 0.9055) 22.980 (0.9047)
Item Standard Limit
Conrod small end I.D. 23.006 – 23.014 (0.9057 – 0.9061) 23.040 (0.9071)
Conrod deflection 3.0 (0.12)
Conrod big end side clearance 0.10 – 0.75 (0.004 – 0.030) 1.0 (0.04)
Conrod big end width 24.95 – 25.00 (0.982 – 0.984)
Crank web to web width 72.9 – 73.1 (2.87 – 2.88)
Crankshaft runout 0.08 (0.003)
Item Standard Limit
Oil pressure (at 60 °C, 140 °F)
140 – 180 kPa
(1.4 – 1.8 kgf/cm
2
, 20 – 26 psi)
at 3 000 r/min
Item Standard Limit
Clutch wheel I.D. 140.0 – 140.2 (5.512 – 5.520) 140.5 (5.53)
Clutch shoe
No groove at any
part
Clutch engagement r/min 1 500 – 2 000 r/min
Clutch lock-up r/min 3 500 – 4 000 r/min
Service Data: 0C-3
Drive Train
Unit: mm (in) Except ratio
Thermostat + Radiator + Fan + Coolant
Item Standard Limit
Automatic transmission ratio Variable change (2.763 – 0.780)
Secondary reduction ratio 2.158 (40/21 x 17/15)
Final reduction ratio
Front 3.600 (36/10)
Rear 3.600 (36/10)
Transfer gear ratio
Low 2.562 (41/16)
High 1.240 (31/25)
Reverse 1.882 (32/17)
Drive V-belt width 34.3 (1.35) 33.3 (1.31)
Movable driven face spring free
length
160.0 (6.30) 152.0 (6.00)
Shift fork to groove
clearance
Low 0.10 – 0.30 (0.0040 – 0.0120) 0.50 (0.020)
High 0.10 – 0.30 (0.0040 – 0.0120) 0.50 (0.020)
Reverse 0.10 – 0.30 (0.0040 – 0.0120) 0.50 (0.020)
Shift fork groove
width
Low 5.50 – 5.60 (0.217 – 0.220)
High 5.50 – 5.60 (0.217 – 0.220)
Reverse 5.50 – 5.60 (0.217 – 0.220)
Shift fork thickness
Low 5.30 – 5.40 (0.209 – 0.213)
High 5.30 – 5.40 (0.209 – 0.213)
Reverse 5.30 – 5.40 (0.209 – 0.213)
Front/Rear output shaft bevel gear
backlash
0.03 – 0.15 (0.001 – 0.006)
Front drive (differential) gear
backlash
0.05 – 0.10 (0.002 – 0.004)
Rear drive (final)
gear backlash
Without gear
cover
specification
0.02 – 0.06 (0.0008 – 0.0024)
Gear cover
assembled
specification
0.08 – 0.15 (0.0031 – 0.0059)
Front differential gear oil type Hypoid gear oil SAE #90, API grade GL-5
Rear drive gear oil type Mobil 424 or equivalent gear oil
Front differential gear oil capacity 500 ml (16.9/17.6 US/lmp oz)
Final gear oil capacity 770 ml (26.0/27.1 US/lmp oz)
Item Standard Note
Thermostat valve opening
temperature
Approx. 82 °C (180 °F)
Thermostat valve lift 8 mm (0.31 in) and over at 95 °C (203 °F)
ECT sensor resistance
20 °C
(68 °F)
Approx. 2.45 k
50 °C
(122 °F)
Approx. 0.811 k
80 °C
(176 °F)
Approx. 0.318 k
110 °C
(230 °F)
Approx. 0.142 k
Radiator cap valve opening
pressure
110 – 140 kPa (1.1 – 1.4 kgf/cm
2
, 15.6 – 19.9 psi)
Cooling fan thermo-switch operating
temperature
OFF ON Approx. 93 °C (199 °F)
ON OFF Approx. 87 °C (189 °F)
Engine coolant type
Use an antifreeze/coolant compatible with aluminum
radiator, mixed with distilled water only, at the ratio of 50:50.
Engine coolant
Reservoir Approx. 250 ml (0.26/0.22 US/lmp qt)
Engine Approx. 2 200 ml (2.32/1.94 US/lmp qt)
0C-4 Service Data:
Injector + Fuel Pump + Fuel Pressure Regulator
FI Sensors + Secondary Throttle Valve Actuator
Throttle Body
Item Specification Note
Injector resistance 11 – 13 at 20 °C (68 °F)
Fuel pump discharge amount 55.5 ml (1.88/1.95 US/lmp qt) and more/10 sec.
Fuel pressure regulator operating
set pressure
Approx. 294 kPa (2.9 kgf/cm
2
, 41 psi)
Item Specification Note
CKP sensor resistance 150 – 250
CKP sensor peak voltage 5.0 V and more When cranking
IAP sensor input voltage 4.5 – 5.5 V
IAP sensor output voltage Approx. 2.63 V at idle speed
TP sensor input voltage 4.5 – 5.5 V
TP sensor output voltage
Closed Approx. 1.1 V
Opened Approx. 4.3 V
ECT sensor input voltage 4.5 – 5.5 V
ECT sensor output voltage 0.15 – 4.85 V
ECT sensor resistance Approx. 2.45 k at 20 °C (68 °F)
IAT sensor input voltage 4.5 – 5.5 V
IAT sensor output voltage 0.15 – 4.85 V
IAT sensor resistance Approx. 1.60 k at 20 °C (68 °F)
TO sensor resistance 19 – 20 k
TO sensor voltage
Normal 0.4 – 1.4 V
Leaning 3.7 – 4.4 V When leaning 65°
GP switch voltage 0.6 V and more From 1st to Top
Injector voltage Battery voltage
Ignition coil primary peak voltage 80 V and more When cranking
ISC valve resistance Approx. 31 k at 20 °C (68 °F)
Item Specification
Bore size 42 mm
I.D. No. 31G0
Idle r/min 1 300 ± 100 r/min
Fast idle r/min 1 500 – 2 000 r/min (When cold engine)
Throttle cable play 3 – 5 mm (0.12 – 0.20 in)
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Suzuki LT-A750XP/Z Supplementary Service Manual

Category
Engine
Type
Supplementary Service Manual
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